Heated Garment System

ABSTRACT

A flexible garment system which is capable of emitting heat when an electrical current is applied, comprising an electrically insulating fibre rich base structure ( 4 ) incorporating an electrically and thermally conductive area ( 1 ) and at least two power supply lines ( 2 ). The heating element consists of a woven, knitted or non-woven fabric ( 1 ) containing fibres that are both electrically and thermally conductive. Two or more fabric-based power supply lines ( 2 ) are incorporated to supply the panel with electric current, which are connected to the power supply via suitable electrically conductive fasteners ( 3 ).

TECHNICAL FIELD

The invention relates to a heated garment system and particularly to aflexible, electrically powered heated garment system, which may be inthe form of any item of apparel. Such a garment may be used as astand-alone garment or may have further layers applied to produce moreadvanced garment systems.

BACKGROUND

Existing heated garment systems rely on hard wiring technology toproduce the desired heating effect. The main disadvantage to this isthat it detracts from the aesthetic and comfort aspects of the item.This can be a considerable drawback due to the occlusive nature of anumber of apparel items, in particular intimate apparel. Typically,existing heated garment elements consist of a metal wire or stripsituated in the region where heating is required. Some examples of thesebeing Johnson et al U.S. Pat. No. 3,663,796, Doosung WO030059099 andBala et al US2002146948. The elements are connected to a power supplyvia electrically conductive wires, which are typically bonded to thebody of the garment underneath a layer of fabric.

Previous versions of heated garment systems incorporated a power supplybuilt into a belt to be worn around the waist and hence the connectivitywires ran from the belt along the torso and limb to the garment. Anexample of this is Traffanstedt et al U.S. Pat. No. 4,705,935, where aheated sock is controlled and powered via a unit secured to a beltlocated at the wearer's waist region. This is a very restrictive andinconvenient arrangement. Many versions of heated garments include apocket on the garment itself in which to house the power supply such asthat of Murphy et al U.S. Pat. No. 3,396,264, where the power supply fora heated sock is housed in a pouch located in the welt region. Suchsystems have used bulky, standard domestic batteries as the powersupply. In addition, these garments have also offered the wearer theability to select the desired heating effect by way of a separatecontroller. These systems are unsatisfactory because of the rigidity ofthe heating element component and connectivity wires, and the bulk ofthe power supply. The presence of these rigid and bulky components cancause considerable discomfort to the wearer. Both of these are majordrawbacks, particularly for apparel intended to be worn next to theskin.

These prior art garments are not exhaustive but are exemplary of thestate of the art. While such prior art devices provide an active heatingeffect in a resulting garment there exists a need for a heated garmentsystem that lends itself to conventional methods of garment manufacture,and is thus commercially and economically viable, and retains all of thephysical and aesthetic properties associated with such garments.

OBJECT OF THE INVENTION

An object of this invention is to provide a heated garment system, whichis capable of emitting heat when an electrical current is applied. Thegarment system should retain the aesthetic and durability properties ofconventional garments but also provide a new level of functionalitythrough the incorporation of an unobtrusive heating element or should atleast provide the public with a useful choice.

Such garments may be worn both indoors and outdoors as a conventionalgarment or, via the portable power supply and controller, be used as anactive heating device.

SUMMARY OF THE INVENTION

The invention provides a heated garment system produced via a knitting,weaving, or non-woven process where the heating area and connectivitycomponents are incorporated into the system during fabric manufacture.

In particular, the invention provides a heated garment system that isproduced in a single manufacturing process.

More particularly, the invention provides a flexible garment systemwhich is capable of emitting heat when an electrical current is applied,comprising an electrically insulating fibre base structure with anelectrically and thermally conductive area and at least two power supplylines, all of which are incorporated during the textile manufacturestage.

The electrically insulating base may be woven, knitted or non-wovenfabric made of natural, regenerated or synthetic fibres.

The complete system contains a majority of electrically insulatingfibres, with a minority of electrically and thermally conductive yarnsor fibres.

The electrically and thermally conductive heater area may be composed ofone of the following fibres:

-   -   1) Metal fibres    -   2) Carbon fibres    -   3) Metallised polymer fibres    -   4) Conductive polymer coated fibres    -   5) Conductive polymer fibres    -    or from a combination of these materials.

The electrically and thermally conductive heater area may be composed offibres as described above blended with fibres as described above.

The system may be powered by connection to a self-contained powersupply.

There may be a further base structure with a thermally conductive areaapplied to this from a more advanced garment system.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will now be described by way of example only and withreference to the accompanying drawing in which:

FIG. 1 shows the active garment system

FIG. 2 shows the heater section within the garment

As shown in FIG. 1, the heated garment comprises a flexible fabric-basedsystem. This may consist of either a single or a multi-layer fabricarrangement depending upon both the form of the garment and itspotential working environment. The heating element is integrated intothe textile structure during knitting, weaving or nonwovenmanufacturing. The base garment (4) is constructed from fibre that isnot electrically conductive, while the heating element (1) isconstructed from a blend of non-conductive fibres with electrically andthermally conductive fibres. Two or more yarn-based power supply lines(2) are incorporated to supply the panel with electric current. Theseare directly connected to a controller and power supply via electricallyconductive fasteners (3).

As shown in FIG. 2, the heating element extends to cover the areas ofthe garment where an active heating effect is desirable. The power lines(2) are incorporated into the base structure of the garment and run fromthe electrical connectors to either side of the heating element. Theinvention is designed to be powered via a compact portable power supplyand control unit with appropriate voltage and current transformations(not shown).

It is to be understood that the drawings and descriptions are designedsolely for the purposes of illustration and not as a definition of thelimits of the invention, for which reference should be made to theclaims.

EXAMPLE 1

A heated sock with the base structure consisting of electricallyinsulating material, natural and/or synthetic fibres, with a conductivearea, composed of stainless steel fibres blended with natural and/orsynthetic fibres, with two or more fabric power lines. When electricityis supplied to the garment the element emits heat.

EXAMPLE 2

As per Example 1 except the conductive area is composed of carbon fibrethat may be blended with natural and/or synthetic fibres.

EXAMPLE 3

As per Examples 1 and 2 but in the form of a tube of any diameter whichmay be used in the treatment of orthopaedic, arthritic and rheumaticconditions.

EXAMPLE 4

As per Examples 1 and 2 but in the form of an athletic bandage, whichmay be used in the treatment of sports injuries.

EXAMPLE 5

A heated glove where the base structure and electrically and thermallyconductive areas form a layer within a multi-layer garment system.

EXAMPLE 6

A heated vest consisting of a base structure and an electrically andthermally conductive area as described in Example 1.

INDUSTRIAL APPLICABILITY

The invention provides a heated garment product with aesthetic andperformance properties of conventional garments. The product can be usedin the form of a sock, glove, vest, body vest, long-john, bandage orsupport, or other garment for personal wear or use or in the form oflayers for more advanced garment systems.

1. A flexible garment system which is capable of emitting heat when anelectrical current is applied, comprising an electrically insulatingfibre base structure with an electrically and thermally conductive areaand at least two power supply lines, all of which are incorporatedduring the textile manufacture stage.
 2. A garment as described in claim1 where the electrically insulating base structure is woven, knitted ornon-woven fabric made of natural, regenerated or synthetic fibres.
 3. Agarment as described in claim 1 where the electrically and thermallyconductive area may be a woven, knitted or non-woven fabric made of oneof the following fibres: a.) Metal fibres b.) Carbon fibres c.)Metallised polymer fibres d.) Conductive polymer coated fibres e.)Conductive polymer fibres f.) or from a combination of these materials.4. A garment as described in claim 1 wherein the electrically andthermally conductive area comprises a woven, knitted or non-woven fabricmade of fibres selected from the group consisting of metal fibres,carbon fibres, metallised polymer fibres, conductive polymer coatedfibres, conductive polymer fibres and a combination thereof, blendedwith a woven, knitted or non-woven fabric made of natural, regeneratedor synthetic fibres.
 5. A garment as described in claim 1 that is powerby connection to a self-contained power supply.
 6. A garment accordingto claim 1 which has a further base structure with a thermallyconductive area applied to thus form a more advanced garment system.